Method for Manufacturing Faucet and Faucet Produced Thereby

ABSTRACT

The present invention relates to a method for manufacturing a faucet including the steps of: preparing metallic parts and non-metallic parts, the non-metallic parts having a manifold, and cool and hot water flow path pipes; coupling the cool and hot water flow path pipes to the manifold or coupling the cool and hot water flow path pipes to flow connection members and the manifold; molding the manifold in such a manner as to inject a liquid type ABS resin into a space portion of a double injection mold and to fill the space portion with the ABS resin, so that the manifold to which the cool and hot water flow path pipes are coupled is surrounded with a body; and assembling the body in which the manifold coupled to the cool and hot water flow path pipes is accommodated to other parts constituting the faucet.

RELATED APPLICATIONS

This application claims the benefit of Korean 1 application10-2014-0068078 filed on Jun. 5, 2014 and entitled “Method forManufacturing Faucet and Faucet Produced Thereby,” the content of whichis hereby incorporated by reference in its entirety and for allpurposes.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method for manufacturing acontrolling valve (hereinafter, which is referred to as ‘faucet’), andmore particularly, to a method for manufacturing a faucet mounted on awash basin, bathtub, shower, and kitchen sink to supply water therefromand to a faucet produced by the method.

2. Background of the Related Art

Generally, a faucet is mounted on a wash basin, bathtub, shower, andkitchen sink to supply hot and cool water to a user, while beingcooperatively operated with a boiler.

That is, the faucet is connected to the front end portions of buriedcool and hot water pipes, irrespective of a specific position, andperforms the supply of cool and hot water, the stop of the supply, andthe free adjustment of the mixed amount of the cool and hot water bymeans of the manipulation of an opening/closing lever, thus supplyingthe cool and hot water to a user with his or her desired watertemperature and his or her desired quantity of water discharged from thefaucet.

Generally, the faucet has cool and hot water inlet pipes into which coolwater and hot water are introduced, a water outlet pipe of mixed water,and adjusting parts performing the supply of cool and hot water, thestop of the supply, and the adjustment of water temperature and quantityof water discharged by means of the manipulation of the opening/closinglever, while having respective different positions in accordance withthe use purposes thereof, that is, the use purposes of kitchen sink,wash basin and bathtub of bathroom, and kitchen sink. However, thetypical faucets have the same configurations as each other in such amanner as to perform the supply of cool and hot water, the stop of thesupply, the quantity of mixed water, and the supply of mixed waterthrough the adjustment of the quantity of water discharged.

Generally, the faucet includes a body and a plurality of parts (valves,opening/closing lever, packing, connection hose and the like) combinedto each other, and the body is made of brass easily moldable.

The faucet made through the molding should form passages at the insidethereof, through which the mixed water having a given temperature undera user's adjustment flows via the cool and hot water flow path pipes andthe adjusting parts, and accordingly, the body is molded in the statewhere the passages communicate with each other on one side surfacethereof. Further, a separate sealing part is coupled to the open portionof one side surface of the body molded so as to seal the open portion ofthe body, without having any leakage of water.

However, the molding work for making the body of the faucet may causeserious environmental pollution, and further, harmful components(graphite and impurities) may remain on the body of the faucet accordingto the characteristics of the molding work, so that when the faucet isused as a product, the harmful components may be mixed with the waterdischarged from the faucet. Additionally, since the molding work for thefaucet is generally conducted in weak circumstances, manufacturers arereluctant to do the molding work.

On the other hand, while the body of the faucet is being used as aproduct for a long period of time, it may be decayed to a higher degreethan that of the body of the faucet as an initial product due to tapwater, thus causing serious sanitary problems.

When hot water is used, moreover, heat is fast transmitted to the faucetbody made of brass, and at this time, if the old and the weak or thechildren are contacted with the hot faucet body, they may easily getburnt.

So as to remove the above-mentioned problems, recently, a faucet made ofa synthetic resin, not through molding, has been introduced and usedthrough simple adjustment.

According to the configuration of the conventional faucet, for example,cool and hot water flow path pipes fastened to cool and hot water pipesto flow cool and hot water therethrough, a mixing pipe connected to thecool and hot water flow path pipes to mix the cool and hot water witheach other, and a water discharging pipe discharging the water mixed inthe mixing pipe are separately connected to have given shapes accordingto the use purposes of the faucet, and they are fastened surroundedly tosegmented bodies by means of fastening screws, thus taking a given shapeof the faucet.

Since the faucet made of the synthetic resin does not have any moldingwork, it can solve the above-mentioned problems and can be easily made,thus enhancing the manufacturing cost and the productivity, but whilethe faucet made of the synthetic resin is being frequently contactedwith cool and hot water, harmful components of the synthetic resin maybe supplied to a user, in the state of being contained in the cool andhot water, due to the chemical reaction with chlorine contained inwater.

SUMMARY OF THE INVENTION

Accordingly, the present invention has been made in view of theabove-mentioned problems occurring in the prior art, and it is an objectof the present invention to provide a method for manufacturing a faucetthat is capable of reducing the manufacturing cost thereof.

It is another object of the present invention to provide a method formanufacturing a faucet that is capable of preventing harmful componentsof a synthetic resin from being supplied to a user in the state of beingcontained in cool and hot water, while the faucet made of the syntheticresin is being frequently contacted with the cool and hot water.

It is yet another object of the present invention to provide a methodfor manufacturing a faucet that is capable improving the productivitythrough double injection molding and also decreasing the failure rate inmanufacturing process.

It is still another object of the present invention to provide a methodfor manufacturing a faucet that is capable of preventing the old, theweak and the children from getting burnt even while they use hot water.

It is another object of the present invention to provide a method formanufacturing a faucet that is capable of improving the manufacturingworkability thereof.

It is yet another object of the present invention to provide a methodfor manufacturing a faucet that is capable of preventing cool and hotwater flow path pipes from being twisted while in use.

It is still another object of the present invention to provide a methodfor manufacturing a faucet that is capable of removing separate processlike welding or soldering in the assembling process of the parts of thefaucet.

It is yet still another object of the present invention to provide amethod for manufacturing a faucet that is capable of enhancing theworkability thereof and the outer appearance thereof.

To accomplish the above-mentioned objects, according to a first aspectof the present invention, there is provided a method for manufacturing afaucet including the steps of: preparing metallic parts and non-metallicparts for making the faucet, the non-metallic parts having a manifoldadapted to supply cool and hot water supplied thereto to a controllingmember, and cool and hot water flow path pipes; coupling the cool andhot water flow path pipes to the manifold or coupling the cool and hotwater flow path pipes to flow connection members and the manifold;molding the manifold to which the cool and hot water flow path pipes andthe flow path connection members are coupled or the manifold to whichthe cool and hot water flow path pipes are coupled in such a manner asto inject a liquid type ABS resin into a space portion of a doubleinjection mold and to fill the space portion with the ABS resin, so thatthe manifold to which the cool and hot water flow path pipes are coupledis surrounded with a body; and assembling the body in which the manifoldcoupled to the cool and hot water flow path pipes is accommodated toother parts constituting the faucet.

According to the present invention, preferably, the cool and hot waterflow path pipes are made of a polypropylene (PP) or polyethylene (PE)resin by means of injection molding.

According to the present invention, preferably, the cool and hot waterflow path pipes are L-shaped, while having a square cross-section, andthe manifold has coupling grooves adapted to connect one end portion ofthe cool and hot water flow path pipes thereto.

According to the present invention, preferably, the cool and hot waterflow path pipes are linearly formed, while having a squarecross-section, in such a manner as to be connected to coupling groovesof the manifold on one end portion thereof and to the flow pathconnection members on the other end portion thereof, the flow pathconnection members being made of a polypropylene (PP) or polyethylene(PE) resin.

According to the present invention, preferably, the manifold is made ofa polypropylene (PP) or polyethylene (PE) resin, and the body is made ofan ABS resin.

To accomplish the above-mentioned objects, according to a second aspectof the present invention, there is provided a method for manufacturing afaucet including the steps of: preparing metallic parts and non-metallicparts for making the faucet, the non-metallic parts having a manifoldadapted to supply cool and hot water supplied thereto to a controllingmember, and cool and hot water flow path pipes; coupling the cool andhot water flow path pipes to the manifold; molding the manifold to whichthe cool and hot water flow path pipes are coupled in such a manner asto inject a liquid type ABS resin into a space portion of a doubleinjection mold and to fill the space portion with the ABS resin, so thatthe manifold to which the cool and hot water flow path pipes are coupledis surrounded with a body; and assembling the body in which the manifoldcoupled to the cool and hot water flow path pipes is accommodated toother parts constituting the faucet.

According to the present invention, preferably, the cool and hot waterflow path pipes include horizontal members arranged in parallel with thebody, vertical members extended vertically from the end portions of thehorizontal members, and extension members formed unitarily with theconnection portions between the horizontal members and the verticalmembers.

According to the present invention, preferably, the extensions membersare sealed by means of fitting members formed on both sides of the bodyin such a manner as to be passed through the body.

To accomplish the above-mentioned objects, according to a third aspectof the present invention, there is provided a method for manufacturing afaucet including the steps of: preparing metallic parts and non-metallicparts for making the faucet, the non-metallic parts having a manifoldadapted to supply cool and hot water supplied thereto to a controllingmember, cool and hot water flow path pipes, a lower body and an upperbody; coupling the cool and hot water flow path pipes to the manifold orcoupling the cool and hot water flow path pipes to flow connectionmembers and the manifold; molding the manifold to which the cool and hotwater flow path pipes and the flow path connection members are coupledor the manifold to which the cool and hot water flow path pipes arecoupled in such a manner as to inject a liquid type ABS resin into aspace portion of a double injection mold and to fill the space portionwith the ABS resin, so that the manifold to which the cool and hot waterflow path pipes are coupled is surrounded with the lower body and theupper body; and assembling the lower body and the upper body in whichthe manifold coupled to the cool and hot water flow path pipes isaccommodated to other parts constituting the faucet.

To accomplish the above-mentioned objects, according to a fourth aspectof the present invention, there is provided a method for manufacturing afaucet including the steps of: preparing metallic parts and non-metallicparts for making the faucet, the non-metallic parts having a manifoldadapted to supply cool and hot water supplied thereto to a controllingmember, cool and hot water flow path pipes, and upper and lowerdischarging pipes having coupling protrusions formed on the front endportions thereof; coupling the upper and lower discharging pipes and thecool and hot water flow path pipes to the manifold; molding the manifoldto which the upper and lower discharging pipes and the cool and hotwater flow path pipes are coupled in such a manner as to inject a liquidtype ABS resin into a space portion of a double injection mold and tofill the space portion with the ABS resin, so that the manifold to whichthe upper and lower discharging pipes and the cool and hot water flowpath pipes are coupled is surrounded with a body; and assembling thebody in which the manifold coupled to the cool and hot water flow pathpipes is accommodated to other parts constituting the faucet, whereinthe manifold, the upper and lower discharging pipes, and the cool andhot water flow path pipes are made of a polypropylene (PP) orpolyethylene (PE) resin, and the manifold has a coupling protrusionformed unitarily with one side of the outer peripheral surface thereof.

To accomplish the above-mentioned objects, according to a fifth aspectof the present invention, there is provided a method for manufacturing afaucet including the steps of: preparing metallic parts and non-metallicparts for making the faucet, the non-metallic parts having a manifoldadapted to supply cool and hot water supplied thereto to a controllingmember, cool and hot water flow path pipes, and a discharging pipe;coupling upper and lower flow path pipes constituting the dischargingpipe and the cool and hot water flow path pipes to the manifold; moldingthe manifold to which the upper and lower flow path pipes and the cooland hot water flow path pipes are coupled in such a manner as to injecta liquid type ABS resin into a space portion of a double injection moldand to fill the space portion with the ABS resin, so that the manifoldto which the upper and lower flow path pipes and the cool and hot waterflow path pipes are coupled is surrounded with a body; and assemblingthe body in which the manifold coupled to the cool and hot water flowpath pipes is accommodated to other parts constituting the faucet,wherein the manifold, the cool and hot water flow path pipes, and theupper and lower flow path pipes are made of a polypropylene (PP) orpolyethylene (PE) resin, and the manifold has a coupling protrusionformed unitarily with one side of the outer peripheral surface thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and advantages of the presentinvention will be apparent from the following detailed description ofthe preferred embodiments of the invention in conjunction with theaccompanying drawings, in which:

FIGS. 1 and 2 are exploded perspective views showing a faucetmanufactured by a method for manufacturing the faucet according to afirst embodiment of the present invention;

FIG. 3 is an exploded perspective view showing a faucet manufactured bya method for manufacturing the faucet according to a second embodimentof the present invention;

FIGS. 4 and 5 are exploded perspective views showing a faucetmanufactured by a method for manufacturing the faucet according to athird embodiment of the present invention;

FIG. 6 is a flow chart showing the method for manufacturing the faucetaccording to the first embodiment of the present invention;

FIGS. 7 and 8 are exploded perspective views showing a faucetmanufactured by a method for manufacturing the faucet according to afourth embodiment of the present invention; and

FIG. 9 is an exploded perspective view showing a faucet manufactured bya method for manufacturing the faucet according to a fifth embodiment ofthe present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, an explanation on a method for manufacturing a faucetaccording to the present invention will be in detail given withreference to the attached drawing.

In the description, the terms as will be discussed later are defined inaccordance with the functions of the present invention, but may bevaried under the intention or regulation of a user or operator.Therefore, they should be defined on the basis of the whole scope of thepresent invention.

First Embodiment

FIGS. 1 and 2 are exploded perspective views showing a faucetmanufactured by a method for manufacturing the faucet according to afirst embodiment of the present invention and FIG. 6 is a flow chartshowing the method for manufacturing the faucet according to the firstembodiment of the present invention. At this time, the correspondingparts in FIGS. 1 and 2 are indicated by corresponding referencenumerals.

Referring to FIGS. 1 and 2, a method for manufacturing a faucetaccording to a first embodiment of the present invention includes partpreparing step S11, cool and hot water flow path pipe coupling step S12,double injection molding step S13, and assembling step S14.

First, parts for manufacturing a faucet are prepared (at step S11). Atthis time, the parts include metallic parts and non-metallic parts. Themetallic parts include a pair of eccentric sets 110 connected to cooland hot water pipes (not shown) installed on a wall surface, adischarging pipe 120 discharging cool and hot water and mixed watertherefrom, a water outlet 122 formed unitarily with the discharging pipe120 to provide the cool and hot water and the mixed water moving throughthe discharging pipe 120 for a user, and an opening/closing lever 130.

On the other hand, the non-metallic parts include a controlling member140 (which is called a cartridge) adapted to control the supply anddischarge of the cool and hot water and the mixed water; adjustingmembers, that is, manifolds 150 and 250 adapted to seat the controllingmember 140 therein to provide the supplied cool and hot water to thecontrolling member 140, cool water flow path pipes 260 and 360, and hotwater flow path pipes 270 and 370.

At this time, the cool water flow path pipes 260 and 360 and the hotwater flow path pipes 270 and 370 are made of a polypropylene (PP) orpolyethylene (PE) resin having no ill effects on the human by means ofinjection molding.

Referring first to FIG. 1, the cool and hot water flow path pipes 260and 270 are L-shaped, while having a square cross-section, and themanifold 250 has coupling grooves 252 having a square cross-sectionadapted to connect one end portion of the cool and hot water flow pathpipes 260 and 270 thereto. At this time, there are no separate O-ringsfor coupling the cool and hot water flow path pipes 260 and 270 with themanifold 250. As mentioned above, if the cool and hot water flow pathpipes 260 and 270 have the square cross-sectional shape, they are nottwisted at all while in use.

Referring to FIG. 2, next, the cool and hot water flow path pipes 360and 370 are linearly formed, while having a square cross-sectionalshape, and they are connected to coupling grooves 152 of the manifold150 on one end portion thereof, while being connected to separate flowpath connection members 180 on the other end portion thereof. The flowpath connection members 180 have a generally rectangular shape in such amanner as to be connected to the cool and hot water flow path pipes 360and 370 on one side thereof and connected to the cool and hot waterpipes mounted on the wall surface through a body 100 and connectionpieces 102 on the other side thereof.

At this time, the manifold 150 is made of a polypropylene (PP) orpolyethylene (PE) resin having no ill effects on the human by means ofinjection molding, and the body 100 is made of an ABS resin in view ofmanufacturing cost and productivity.

After that, the prepared parts, that is, the cool and hot water flowpath pipes are coupled to each other (S12). As shown in FIG. 1, the cooland hot water flow path pipes 260 and 270 are coupled to the manifold250, or, as shown in FIG. 2, the cool and hot water flow path pipes 360and 370 are coupled to the flow path connection members 180 and themanifold 150.

At this time, the flow path connection members 180 are made of thepolypropylene (PP) or polyethylene (PE) resin having no ill effects onthe human.

Next, the manifold 150 to which the cool and hot water flow path pipes360 and 370 and the flow path connection members 180 are coupled or themanifold 250 to which the cool and hot water flow path pipes 260 and 270are coupled is molded in such a manner as to inject a liquid type ABSresin into a space portion of a double injection mold (not shown) and tofill the space portion with the ABS resin (at step S13), so that themanifold 150 or 250 to which the cool and hot water flow path pipes 260,360 and 270, 370 are coupled is surrounded with the body 100 designed tohave a given shape.

After that, the body 100 in which the manifolds 150 or 250 coupled tothe cool water flow path pipes 260 and 360 and the hot water flow pathpipes 270 and 370 is accommodated is assembled to other partsconstituting the faucet.

That is, the eccentric sets 110 are connected to the cool and hot waterpipes, and then, the body 100 is connected to the eccentric sets 110 bymeans of the connection pieces 102 and packings 112 disposed on the rearsurface thereof.

Further, the controlling member 140 connected to the manifold 150 or 250and the opening/closing lever 130 are assembled to the top surface ofthe body 100, and the discharging pipe 120 is assembled to the frontsurface of the body 100.

If water is turned on through the manipulation of the opening/closinglever 130 of the faucet assembled in the above-mentioned manner, thecontrolling member 140 disposed in the body 100 is open to allow cooland hot water to be mixed therein through the manifolds 150 or 250connected to the cool water flow path pipes 260 and 360 and the hotwater flow path pipes 270 and 370, and next, the mixed water is suppliedto the user through the manifold 150 or 250 and the water outlet 122 ofthe discharging pipe 120.

According to the faucet manufactured in the above-mentioned process, thecool water flow path pipes 260 and 360 and the hot water flow path pipes270 and 370, along which the cool and hot water and the mixed watermove, are made of the polypropylene (PP) or polyethylene (PE) resinhaving no ill effects on the human, and further, the body 100 is made ofthe ABS resin capable of reducing the manufacturing cost (up to about50%).

Further, the cool water flow path pipes 260 and 360 and the hot waterflow path pipes 270 and 370 are made of the polypropylene (PP) orpolyethylene (PE) resin having no ill effects on the human, thuspreventing the harmful components of a synthetic resin from beingsupplied to the user in the state of being contained in the cool and hotwater while they are being frequently contacted with the cool and hotwater.

Furthermore, the cool water flow path pipes 260 and 360 and the hotwater flow path pipes 270 and 370 are manufactured by means of doubleinjection molding, thus improving the productivity and decreasing thefailure rate in manufacturing process.

Additionally, the body 100 is made of the ABS resin, thus preventing theold, the weak and the children from getting burnt even while they usehot water.

Further, the O-rings used in the assembling process of the conventionalfaucet are not needed at all, thus improving the manufacturingworkability.

Also, since the cool water flow path pipes 260 and 360 and the hot waterflow path pipes 270 and 370 have the square cross-sectional shapes, theyare not twisted at all while in use.

Moreover, no separate process like welding or soldering in theassembling process of the parts of the faucet is required anymore.

Second Embodiment

FIG. 3 is an exploded perspective view showing a faucet manufactured bya method for manufacturing the faucet according to a second embodimentof the present invention. At this time, the corresponding parts in FIG.3 to those in FIGS. 1 and 2 are indicated by corresponding referencenumerals to each other.

In the same manner as in the first embodiment of the present invention,a method for manufacturing a faucet according to a second embodiment ofthe present invention includes the part preparing step, the cool and hotwater flow path pipe coupling step, the double injection molding step,and the assembling step.

In the part preparing step, first, metallic parts and non-metallic partsare prepared.

The metallic parts include eccentric sets 110, a discharging pipe 120, awater outlet 122, and an opening/closing lever 130.

On the other hand, the non-metallic parts include a controlling member140, a manifold 250, a cool water flow path pipe 560, and a hot waterflow path pipe 570. At this time, the manifold 250 is made of apolypropylene (PP) or polyethylene (PE) resin by means of injectionmolding, the cool water flow path pipe 560 and the hot water flow pathpipe 570 are made of a polypropylene (PP) or polyethylene (PE) resin bymeans of injection molding, and a body 100 is made of an ABS resin.

Referring to FIG. 3, the cool water flow path pipe 560 and the hot waterflow path pipe 570 include horizontal members 562 and 572 arranged inparallel with the body 100 and vertical members 564 extended verticallyfrom the end portions of the horizontal members 562 and 572. Further,extension members 566 are formed unitarily with the connection portionsbetween the horizontal members 562 and 572 and the vertical members 564.The vertical member and the extension members of the hot water flow pathpipe 570 are not shown in FIG. 3.

Further, the vertical members 564 of the cool water flow path pipe 560and the hot water flow path pipe 570 are connected to the cool and hotwater pipes through the body 100 and connection pieces 102, and thehorizontal members 562 and 572 are connected to the manifold 250.

Furthermore, the extensions members 566 are sealed by means of fittingmembers 480 formed on both sides of the body 100 in such a manner as tobe passed through the body 100.

Also, the cool and hot water flow path pipes 560 and 570 have a squarecross-sectional shape, thus preventing the twisting while in use.

Moreover, the manifold 250 has coupling grooves 252 having a squarecross-section, and at this time, there are no separate O-rings forcoupling the cool and hot water flow path pipes 560 and 570 with themanifold 250.

Further, the fitting members 480 have a circular cross-sectional shape,but desirably, they have a square cross-sectional shape so as to enhancetheir sealing effects.

After that, the prepared parts, that is, the cool and hot water flowpath pipes 560 and 570 are coupled to the manifold 250.

Next, the manifold 250 to which the cool and hot water flow path pipes560 and 570 are connected is molded in such a manner as to inject aliquid type ABS resin into a space portion of a double injection mold(not shown) and to fill the space portion with the ABS resin, so thatthe manifold 250 to which the cool and hot water flow path pipes 560 and570 are connected is surrounded with the body 100 designed to have agiven shape.

After that, the body 100 in which the manifold 250 coupled to the cooland hot water flow path pipes 560 and 570 is accommodated is assembledto other parts constituting the faucet.

That is, the eccentric sets 110 are connected to the cool and hot waterpipes, and then, the body 100 is connected to the eccentric sets 110 bymeans of connection pieces 102 disposed on the rear surface thereof.

Further, the controlling member 140 connected to the manifold 250 andthe opening/closing lever 130 are assembled to the top surface of thebody 100, and the discharging pipe 120 is assembled to the front surfaceof the body 100.

If water is turned on through the manipulation of the opening/closinglever 130 of the faucet assembled in the above-mentioned manner, thecontrolling member 140 disposed in the body 100 is open to allow cooland hot water to be mixed therein through the manifold 250 connected tothe cool and hot water flow path pipes 560 and 570, and next, the mixedwater is supplied to the user through the manifold 250 and the wateroutlet 122 of the discharging pipe 120.

According to the faucet manufactured in the above-mentioned process, thecool and hot water flow path pipes 560 and 570, along which the cool andhot water and the mixed water move, are made of the polypropylene (PP)or polyethylene (PE) resin, and further, the body 100 is made of the ABSresin capable of reducing the manufacturing cost.

Further, the cool and hot water flow path pipes 560 and 570 are made ofthe polypropylene (PP) or polyethylene (PE) resin having no ill effectson the human, thus preventing the harmful components of a syntheticresin from being supplied to the user in the state of being contained inthe cool and hot water while they are being frequently contacted withthe cool and hot water.

Furthermore, the cool and hot water flow path pipes 560 and 570 aremanufactured by means of double injection molding, thus improving theproductivity and decreasing the failure rate in manufacturing process.

Additionally, the body 100 is made of the ABS resin, thus preventing theold, the weak and the children from getting burnt even while they usehot water.

Further, the O-rings used in the assembling process of the conventionalfaucet are not needed at all, thus improving the manufacturingworkability, and also, since the cool and hot water flow path pipes 560and 570 have the square cross-sectional shape, they are not twisted atall while in use.

Moreover, no separate process like welding or soldering in theassembling process of the parts of the faucet is required anymore.

Third Embodiment

FIGS. 4 and 5 are exploded perspective views showing a faucetmanufactured by a method for manufacturing the faucet according to athird embodiment of the present invention. At this time, thecorresponding parts in FIGS. 4 and 5 to those in FIGS. 1 and 2 areindicated by corresponding reference numerals to each other.

In the same manner as in the first embodiment of the present invention,a method for manufacturing a faucet according to a third embodiment ofthe present invention includes the part preparing step, the cool and hotwater flow path pipe coupling step, the double injection molding step,and the assembling step.

In the part preparing step, first, metallic parts and non-metallic partsare prepared.

The metallic parts include eccentric sets 110, a discharging pipe 120, awater outlet 122, and an opening/closing lever 130.

The non-metallic parts include a controlling member 140, manifolds 150and 250, cool water flow path pipes 260 and 360, hot water flow pathpipes 270 and 370, a lower body 100-1 and an upper body 100-2. At thistime, the manifolds 150 and 250 are made of a polypropylene (PP) orpolyethylene (PE) resin having no ill effects on the human by means ofinjection molding, and the lower body 100-1 and the upper body 100-2 aremade of an ABS resin in view of manufacturing cost and productivity.

First, the cool water flow path pipes 260 and 360 and the hot water flowpath pipes 270 and 370 are made of the polypropylene (PP) orpolyethylene (PE) resin having no ill effects on the human by means ofinjection molding, and they have the square cross-sectional shape, thuspreventing the occurrence of twisting while in use.

Referring first to FIG. 4, the cool and hot water flow path pipes 260and 270 are connected to coupling grooves 252 formed on the manifold 250on one end portion thereof.

Referring to FIG. 5, next, the cool and hot water flow path pipes 360and 370 are connected to coupling grooves 152 formed on the manifold 150on one end portion thereof and to flow path connection members 180 onthe other end portion thereof. The flow path connection members 180 areconnected to the cool and hot water flow path pipes 360 and 370 on oneside thereof and connected to the cool and hot water pipes mounted on awall surface through the lower body 100-1 and the upper body 100-2 andconnection pieces 102 on the other side thereof.

After that, the prepared parts, that is, the cool and hot water flowpath pipes are coupled to each other. As shown in FIG. 4, the cool andhot water flow path pipes 260 and 270 are coupled to the manifold 250,or, as shown in FIG. 5, the cool and hot water flow path pipes 360 and370 are coupled to the flow path connection members 180 and the manifold150.

At this time, the flow path connection members 180 are made of thepolypropylene (PP) or polyethylene (PE) resin having no ill effects onthe human.

Next, the manifold 150 or 250 to which the cool water flow path pipes260 and 360 and the hot water flow path pipes 270 and 370 are connectedor to which the cool water flow path pipes 260 and 360 and the hot waterflow path pipes 270 and 370 and the flow path connection members 180 areconnected is molded in such a manner as to inject a liquid type ABSresin into a space portion of a double injection mold (not shown) and tofill the space portion with the ABS resin, so that the manifold 150 or250 to which the cool water flow path pipes 260 and 360 and the hotwater flow path pipes 270 and 370 are connected is surrounded with thelower body 100-1 and the upper body 100-2.

After that, the lower body 100-1 and the upper body 100-2 in which themanifold 150 or 250 coupled to the cool water flow path pipes 260 and360 and the hot water flow path pipes 270 and 370 is accommodated areassembled to other parts constituting the faucet.

That is, the eccentric sets 110 are connected to the cool and hot waterpipes disposed on the wall surface, and then, the lower body 100-1 andthe upper body 100-2 are connected to the eccentric sets 110 by means ofthe connection pieces 102 and packings 112 disposed on the rear surfaceof the coupled portion therebetween.

Further, the controlling member 140 connected to the manifold 150 or 250and the opening/closing lever 130 are assembled to the top surface ofthe coupled portion between the lower body 100-1 and the upper body100-2, and the discharging pipe 120 is assembled to the front surface ofthe coupled portion between the lower body 100-1 and the upper body100-2.

If water is turned on through the manipulation of the opening/closinglever 130 of the faucet assembled in the above-mentioned manner, thecontrolling member 140 is open to allow cool and hot water to be mixedtherein through the manifold 150 or 250 connected to the cool water flowpath pipes 260 and 360 and the hot water flow path pipes 270 and 370,and next, the mixed water is supplied to the user through the manifold150 or 250 and the water outlet 122 of the discharging pipe 120.

On the other hand, the faucets as shown in FIGS. 1 to 5 are applied to abathroom shower, and the eccentric sets 110 are connected to the cooland hot water pipes through a connection member 114 as shown in FIG. 8.

According to the faucet manufactured in the above-mentioned process, thecool water flow path pipes 260 and 360 and the hot water flow path pipes270 and 370, along which the cool and hot water and the mixed watermove, are made of the polypropylene (PP) or polyethylene (PE) resin, andfurther, the lower body 100-1 and the upper body 100-2 are made of theABS resin capable of reducing the manufacturing cost.

Further, the cool water flow path pipes 260 and 360 and the hot waterflow path pipes 270 and 370 are made of the polypropylene (PP) orpolyethylene (PE) resin having no ill effects on the human, thuspreventing the harmful components of a synthetic resin from beingsupplied to the user in the state of being contained in the cool and hotwater while they are being frequently contacted with the cool and hotwater.

Furthermore, the cool water flow path pipes 260 and 360 and the hotwater flow path pipes 270 and 370 are manufactured by means of doubleinjection molding, thus improving the productivity and decreasing thefailure rate in manufacturing process.

Additionally, the lower body 100-1 and the upper body 100-2 are made ofthe ABS resin, thus preventing the old, the weak and the children fromgetting burnt even while they use hot water.

Further, no O-rings are needed, thus improving the manufacturingworkability, and since the cool water flow path pipes 260 and 360 andthe hot water flow path pipes 270 and 370 have the squarecross-sectional shape, they are not twisted at all while in use.

Moreover, no separate process like welding or soldering in theassembling process of the parts of the faucet is required anymore.

Fourth Embodiment

FIGS. 7 and 8 are exploded perspective views showing a faucetmanufactured by a method for manufacturing the faucet according to afourth embodiment of the present invention. At this time, thecorresponding parts in FIGS. 7 and 8 to those in FIGS. 1 and 2 areindicated by corresponding reference numerals to each other.

The faucet as shown in FIG. 7 is applied to a shower, and the faucet asshown in FIG. 8 to a wash basin.

In the same manner as in the first embodiment of the present invention,a method for manufacturing a faucet according to a fourth embodiment ofthe present invention includes the part preparing step, the cool and hotwater flow path pipe coupling step, the double injection molding step,and the assembling step.

In the part preparing step, first, metallic parts and non-metallic partsare prepared.

The metallic parts include an eccentric set 110, a connection member114, a cool water connection pipe 116, a hot water connection pipe 118,and an opening/closing lever 130.

The non-metallic parts include a controlling member (not shown, and seethe reference numeral 140 of FIG. 1), a manifold 350, cool and hot waterflow path pipes 660 and 670, and upper and lower discharging pipes 220and 230. A water outlet (see the reference numeral 122 of FIG. 1) is notshown in FIGS. 7 and 8.

At this time, the manifold 350 is made of a polypropylene (PP) orpolyethylene (PE) resin and has coupling grooves 352 having a squarecross-sectional shape and a coupling protrusion 354 formed unitarilywith one side of the outer peripheral surface thereof.

Further, the upper and lower discharging pipes 220 and 230 aresymmetrical to each other and have coupling protrusions 222 and 232formed on the front end portions thereof, so that when they areconnected to each other by means of bonding or fitting, the couplingprotrusions 222 and 232 are slidingly coupled to the outer surface ofthe coupling protrusion 354 of the manifold 350.

At this time, the upper and lower discharging pipes 220 and 230 are madeof a polypropylene (PP) or polyethylene (PE) resin. They are separatelyformed from each other, as shown in FIGS. 7 and 8, but of course, theymay be formed as a single body.

Also, the cool and hot water flow path pipes 660 and 670 are made of thepolypropylene (PP) or polyethylene (PE) resin. According to the presentinvention, they are separated from each other in a symmetrical relationto each other through first caps 662 and 672 and second caps 664 and674, but of course, they may be formed to have a unitary structure.

Referring first to FIG. 7, the cool and hot water flow path pipes 660and 670 are connected to the coupling grooves 352 formed on the manifold350 on one end portion thereof.

Referring to FIG. 8, next, the cool and hot water flow path pipes 660and 670 are connected to the coupling grooves 352 formed on the manifold350 on one end portion thereof and to the cool water connection pipe 116and the hot water connection pipe 118 on the other end portion thereof.

After that, the prepared parts, that is, the upper and lower dischargingpipes 220 and 230 and the cool and hot water flow path pipes 660 and 670are coupled to the manifold 350.

Next, the manifold 350 to which the upper and lower discharging pipes220 and 230 and the cool and hot water flow path pipes 660 and 670 arecoupled is molded in such a manner as to inject a liquid type ABS resininto a space portion of a double injection mold (not shown) and to fillthe space portion with the ABS resin, so that the manifold 350 issurrounded with a body 100 designed to have a given shape, and the upperand lower discharging pipes 220 and 230 are open through post processafter assembled to each other.

After that, the body 100 in which the manifold 350 coupled to the cooland hot water flow path pipes 660 and 670 is accommodated is assembledto other parts constituting the faucet.

As shown in FIG. 7, that is, the eccentric set 110 is connected to thecool and hot water pipes disposed on the wall surface through theconnection member 114, and then, the body 100 is connected to theeccentric set 110 by means of the connection pieces 102 disposed on therear surface thereof.

Further, the controlling member connected to the manifold 350 and theopening/closing lever 130 are assembled to the top surface of the body100.

As shown in FIG. 8, further, the cool water connection pipe 116 and thehot water connection pipe 118 are connected to the cool and hot waterpipes disposed on the wall surface, and then, the controlling memberconnected to the manifold 350 and the opening/closing lever 130 areassembled to the top surface of the body 100.

If water is turned on through the manipulation of the opening/closinglever 130 of the faucet assembled in the above-mentioned manner, thecontrolling member is open to allow cool and hot water to be mixedtherein through the manifold 350 connected to the cool and hot waterflow path pipes 660 and 670, and next, the mixed water is supplied tothe user through the manifold 350 and the water outlets of the upper andlower discharging pipes 220 and 230.

According to the fourth embodiment of the present invention, the methodfor manufacturing the faucet can remove polishing process. That is, thefaucet as shown in FIGS. 1 to 5 is configured wherein after thedischarging pipe 120 is bonded to the body 100, the bond liquid may leakfrom the space between the machined portions formed on the front endportion of the discharging pipe 120 and the center portion of the body100, thus causing the outer appearance of the faucet to become bad. As aresult, the leaking bond liquid should be removed through a separatepolishing process. According to the fourth embodiment of the presentinvention, however, the upper and lower discharging pipes 220 and 230are formed in a mold through injection molding in the state of beingcoupled to the manifold 350, thus making it unnecessary to perform thepolishing process. As a result, the manufacturing workability isincreased, and the outer appearance of the faucet is improved.

According to the faucet manufactured in the above-mentioned process, thecool and hot water flow path pipes 660 and 670, along which the cool andhot water and the mixed water move, are made of the polypropylene (PP)or polyethylene (PE) resin having no ill effects on the human, andfurther, the body 100 is made of the ABS resin capable of reducing themanufacturing cost.

Further, the cool and hot water flow path pipes 660 and 670 are made ofthe polypropylene (PP) or polyethylene (PE) resin having no ill effectson the human, thus preventing the harmful components of a syntheticresin from being supplied to the user in the state of being contained inthe cool and hot water while they are being frequently contacted withthe cool and hot water.

Furthermore, the cool and hot water flow path pipes 660 and 670 aremanufactured by means of double injection molding, thus improving theproductivity and decreasing the failure rate in manufacturing process.

Additionally, the body 100 is made of the ABS resin, thus preventing theold, the weak and the children from getting burnt even while they usehot water.

Further, no O-rings are needed, thus improving the manufacturingworkability, and since the cool and hot water flow path pipes 660 and670 have the square cross-sectional shape, they are not twisted at allwhile in use.

Moreover, no separate process like welding or soldering in theassembling process of the parts of the faucet is required anymore.

Furthermore, it is unnecessary to perform the polishing process, thusincreasing the manufacturing workability and improving the outerappearance of the faucet.

Fifth Embodiment

FIG. 9 is an exploded perspective view showing a faucet manufactured bya method for manufacturing the faucet according to a fifth embodiment ofthe present invention. At this time, the corresponding parts in FIG. 9to those in FIGS. 7 and 8 are indicated by corresponding referencenumerals to each other, and the faucet as shown in FIG. 9 is a cobrafaucet.

In the same manner as in the first embodiment of the present invention,a method for manufacturing a faucet according to a fifth embodiment ofthe present invention includes the part preparing step, the cool and hotwater flow path pipe coupling step, the double injection molding step,and the assembling step.

In the part preparing step, first, metallic parts and non-metallic partsare prepared.

The metallic parts include an eccentric set 110, a connection member114, and an opening/closing lever 130.

The non-metallic parts include a controlling member (see the referencenumeral 140 of FIG. 1), a manifold 350, cool and hot water flow pathpipes 660 and 670, and a discharging pipe 700 from which cool and hotwater or mixed water is discharged.

At this time, the manifold 350 is made of a polypropylene (PP) orpolyethylene (PE) resin and has coupling grooves 352 having a squarecross-sectional shape and a coupling protrusion 354 formed unitarilywith one side of the outer peripheral surface thereof.

Further, the cool and hot water flow path pipes 660 and 670 are made ofthe polypropylene (PP) or polyethylene (PE) resin by means of injectionmolding, and they are separated from each other in a symmetricalrelation to each other through first caps 662 and 672 and second caps664 and 674. Of course, they may be formed to have a unitary structure.

Further, the cool and hot water flow path pipes 660 and 670 areconnected to the coupling grooves 352 formed on the manifold 350 on oneend portion thereof and to the cool and hot water pipes through theconnection pieces 102 on the other end portion thereof.

The discharging pipe 700 includes upper and lower flow path pipes 710and 720 symmetrical to each other, and in the state where the upper andlower flow path pipes 710 and 720 are connected to each other by meansof bonding or fitting, they are slidingly coupled to the outer surfaceof the coupling protrusion 354 of the manifold 350.

At this time, the upper and lower flow path pipes 710 and 720 are madeof the polypropylene (PP) or polyethylene (PE) resin. They areseparately formed from each other, as shown in FIG. 9, but of course,they may be formed as a single body.

As shown in FIG. 9, the upper and lower flow path pipes 710 and 720 arelinearly formed, but desirably, they have an L-shaped cross-sectionalshape, thus making it easy to be connected to a kitchen cobra as will bediscussed later.

After that, the prepared parts, that is, the upper and lower flow pathpipes 710 and 720 and the cool and hot water flow path pipes 660 and 670are coupled to the manifold 350.

Next, the manifold 350 to which the upper and lower flow path pipes 710and 720 and the cool and hot water flow path pipes 660 and 670 arecoupled is molded in such a manner as to inject a liquid type ABS resininto a space portion of a double injection mold (not shown) and to fillthe space portion with the ABS resin, so that the manifold 350 issurrounded with a body 100 designed to have a given shape.

After that, the body 100 in which the manifold 350 coupled to the cooland hot water flow path pipes 660 and 670 is accommodated is assembledto other parts constituting the faucet.

As shown in FIG. 9, that is, the eccentric set 110 is connected to thecool and hot water pipes disposed on the wall surface through theconnection member 114, and then, the body 100 is connected to theeccentric set 110 by means of the connection pieces 102 disposed on therear surface thereof.

Further, the controlling member connected to the manifold 350 and theopening/closing lever 130 are assembled to the top surface of the body100. At this time, a cobra connector 119 is formed on the center of therear surface of the body 100 so as to connect a kitchen cobra (notshown) thereto, and the cobra connector 119 is open to form an open hole119 a through post processing. Next, the kitchen cobra is connected tothe open hole 119 a.

If water is turned on through the manipulation of the opening/closinglever 130 of the faucet assembled in the above-mentioned manner, thecontrolling member is open to allow cool and hot water to be mixedtherein through the manifold 350 connected to the cool and hot waterflow path pipes 660 and 670, and next, the mixed water is supplied tothe user through the manifold 350, the upper and lower flow path pipes710 and 720, and the kitchen cobra.

According to the faucet manufactured in the above-mentioned process, thecool and hot water flow path pipes 660 and 670, along which the cool andhot water and the mixed water move, are made of the polypropylene (PP)or polyethylene (PE) resin having no ill effects on the human, andfurther, the body 100 is made of the ABS resin capable of reducing themanufacturing cost.

Further, the cool and hot water flow path pipes 660 and 670 are made ofthe polypropylene (PP) or polyethylene (PE) resin having no ill effectson the human, thus preventing the harmful components of a syntheticresin from being supplied to the user in the state of being contained inthe cool and hot water while they are being frequently contacted withthe cool and hot water.

Furthermore, the cool and hot water flow path pipes 660 and 670 aremanufactured by means of double injection molding, thus improving theproductivity and decreasing the failure rate in manufacturing process.

Additionally, the body 100 is made of the ABS resin, thus preventing theold, the weak and the children from getting burnt even while they usehot water.

Further, no O-rings are needed, thus improving the manufacturingworkability, and since the cool and hot water flow path pipes 660 and670 have the square cross-sectional shape, they are not twisted at allwhile in use.

Moreover, no separate process like welding or soldering in theassembling process of the parts of the faucet is required anymore.

As described above, the method for manufacturing the faucet according tothe present invention has the following advantages.

Firstly, the cool and hot water flow path pipes along which the coolwater and the hot water flow are made of the polypropylene (PP) orpolyethylene (PE) resin having no ill effects on the human and the bodyis made of the ABS resin, thus reducing the manufacturing cost thereof.

Secondly, the cool and hot water flow path pipes are made of thepolypropylene (PP) or polyethylene (PE) resin, thus preventing harmfulcomponents of the synthetic resin from being supplied to a user in thestate of being contained in cool and hot water, while they are beingfrequently contacted with the cool and hot water.

Thirdly, high productivity through double injection molding and lowfailure rate in manufacturing process are all achieved.

Fourthly, the body is made of the ABS resin, thus preventing the old andthe weak or the children from getting burnt even while they use hotwater.

Fifthly, the O-rings used in the assembling process of the conventionalfaucet are not needed at all, thus improving the manufacturingworkability.

Sixthly, the cool and hot water flow path pipes have the squarecross-sectional shapes, so that they are not twisted at all while inuse.

Seventhly, no separate process like welding or soldering is needed inthe assembling process of the parts of the faucet.

Lastly, no separate polishing process is needed, thus enhancing theworkability thereof and the outer appearance thereof.

While the present invention has been described with reference to theparticular illustrative embodiments, it is not to be restricted by theembodiments but only by the appended claims. It is to be appreciatedthat those skilled in the art can change or modify the embodimentswithout departing from the scope and spirit of the present invention.

What is claimed is:
 1. A method for manufacturing a faucet, comprisingthe steps of: preparing metallic parts and non-metallic parts for makingthe faucet, the non-metallic parts having a manifold 150 or 250 adaptedto supply cool and hot water supplied thereto to a controlling member140, cool and hot water flow path pipes 260, 360 and 270, 370, a lowerbody 100-1 and an upper body 100-2; coupling the cool and hot water flowpath pipes 260 and 270 to the manifold 250 or coupling the cool and hotwater flow path pipes 360 and 370 to flow connection members 180 and themanifold 150; molding the manifold 150 to which the cool and hot waterflow path pipes 360 and 370 and the flow path connection members 180 arecoupled or the manifold 250 to which the cool and hot water flow pathpipes 260 and 270 are coupled in such a manner as to inject a liquidtype ABS resin into a space portion of a double injection mold and tofill the space portion with the ABS resin, so that the manifold 150 or250 to which the cool and hot water flow path pipes 260, 360 and 270,370 are coupled is surrounded with the lower body 100-1 and the upperbody 100-2; and assembling the lower body 100-1 and the upper body 100-2in which the manifold 150 or 250 coupled to the cool and hot water flowpath pipes 260, 360 and 270, 370 is accommodated to other partsconstituting the faucet.
 2. A method for manufacturing a faucet,comprising the steps of: preparing metallic parts and non-metallic partsfor making the faucet, the non-metallic parts having a manifold 350adapted to supply cool and hot water supplied thereto to a controllingmember 140, cool and hot water flow path pipes 660 and 670, and upperand lower discharging pipes 220 and 230 having coupling protrusions 222and 232 formed on the front end portions thereof; coupling the upper andlower discharging pipes 220 and 230 and the cool and hot water flow pathpipes 660 and 670 to the manifold 350; molding the manifold 350 to whichthe upper and lower discharging pipes 220 and 230 and the cool and hotwater flow path pipes 660 and 670 are coupled in such a manner as toinject a liquid type ABS resin into a space portion of a doubleinjection mold and to fill the space portion with the ABS resin, so thatthe manifold 350 to which the upper and lower discharging pipes 220 and230 and the cool and hot water flow path pipes 660 and 670 are coupledis surrounded with a body 100; and assembling the body 100 in which themanifold 350 coupled to the cool and hot water flow path pipes 660 and670 is accommodated to other parts constituting the faucet, wherein themanifold 350, the upper and lower discharging pipes 220 and 230, and thecool and hot water flow path pipes 660 and 670 are made of apolypropylene (PP) or polyethylene (PE) resin, and the manifold 350 hasa coupling protrusion 354 formed unitarily with one side of the outerperipheral surface thereof.
 3. A method for manufacturing a faucet,comprising the steps of: preparing metallic parts and non-metallic partsfor making the faucet, the non-metallic parts having a manifold 350adapted to supply cool and hot water supplied thereto to a controllingmember 140, cool and hot water flow path pipes 660 and 670, and adischarging pipe 700; coupling upper and lower flow path pipes 710 and720 constituting the discharging pipe 700 and the cool and hot waterflow path pipes 660 and 670 to the manifold 350; molding the manifold350 to which the upper and lower flow path pipes 710 and 720 and thecool and hot water flow path pipes 660 and 670 are coupled in such amanner as to inject a liquid type ABS resin into a space portion of adouble injection mold and to fill the space portion with the ABS resin,so that the manifold 350 to which the upper and lower flow path pipes710 and 720 and the cool and hot water flow path pipes 660 and 670 arecoupled is surrounded with a body 100; and assembling the body 100 inwhich the manifold 350 coupled to the cool and hot water flow path pipes660 and 670 is accommodated to other parts constituting the faucet,wherein the manifold 350, the cool and hot water flow path pipes 660 and670, and the upper and lower flow path pipes 710 and 720 are made of apolypropylene (PP) or polyethylene (PE) resin, and the manifold 350 hasa coupling protrusion 354 formed unitarily with one side of the outerperipheral surface thereof.